Module supply chain

ABSTRACT

A system and method of fabricating and assembling of large-sized modules remote from a heavy industrial hydrocarbon processing plant site, and overland transportation thereof to the plant site. The method may rely on a computer-based heavy-haul transportation logistics system.

RELATED APPLICATION DATA

This application claims priority to U.S. Provisional Patent ApplicationNo. 61/102,130, entitled “Land-Based Refinery Supply Chain,” filed Oct.2, 2008, which is hereby entirely incorporated herein by reference.

BACKGROUND

Petroleum deposits are found throughout the world. In some places, suchas in Alberta and Saskatchewan, Canada, oil sands contain largepetroleum deposits. In Alberta, the oil sands are generally found inthree regions, namely, the Athabasca, Peace River and Cold Lake regions,and cover a total of nearly 34.6 million acres. Alberta has alarge-scale commercial industry devoted to recovering and processing oilsands.

The oil sands of Alberta and Saskatchewan may generally compriseapproximately 10-12 percent bitumen, 80-85 percent mineral matter and4-6 percent water. Thus, producing one barrel of oil may require diggingup, moving and processing more than two tons of oil sand. Processed sandmay then be returned to the recovery site for site reclamation.

Bitumen is a heavy, sticky, black viscous oil. At room temperature,bitumen's viscosity is not unlike that of cold molasses. Bitumen willgenerally not flow unless heated or diluted with lighter hydrocarbons.In comparison to conventional crude oil, which generally flows naturallyor may be pumped from the ground, bitumen generally must be recovered insitu, or “in place.” In situ recovery down to about 250 feet may beaccomplished by open-pit mining. For example, bitumen recovery in theAthabasca region near Fort McMurray, Alberta, involves some of theworld's largest trucks and shovels. Deeper bitumen deposits may requireuse of other techniques that reduce bitumen viscosity by heat orintroduction of solvents.

Such techniques may include cyclic steam stimulation (CSS), which relieson high-pressure steam injected into the oil sand deposit. The heatsoftens the oil sand and the water vapor helps break the bitumen apartfrom the sand. For example, at Cold Lake, oil sands deposits may beheated by steam injection to bring bitumen to the surface, and thendiluted with condensate for shipping by pipelines. Steam-assistedgravity drainage (SAGD), uses two horizontal wells, one several yardsabove the other. Low pressure steam is injected into the upper wellbore,thus heating the bitumen and reducing its viscosity to cause it to draininto the lower wellbore, where it is pumped out. In situ combustion(ISC, or “fireflooding”), such as toe-to-heel air injection, essentiallyburns some of the heavy oil in place to create a combustion zone thatmoves through the oil formation toward the production wells.Electro-thermal dynamic stripping process (ET-DSP), uses electricity toheat oil sands deposits to reduce bitumen viscosity, thus allowingproduction using simple vertical wells. Vapour recovery extraction(VAPEX), uses solvents rather than steam to displace oil and reducebitumen viscosity. Other production techniques may include cold heavyoil production with sand (CHOPS), pressure pulsing techniques (PPT),inert gas injection (IGI), and various hybrids.

Once recovered, bitumen may be processed into an upgraded crude oilbefore it is transported and further refined to gasoline, diesel fuels,and other petroleum products. Bitumen processors may thus be located inclose proximity to the in situ mining operation. Bitumen upgraders maybe massive industrial complexes—for example, covering 1,000 acres ormore—that may require, among other things, vast amounts of piping, largepressure vessels, heaters, pumping stations, holding tanks, meteringdevices, and blending facilities.

Bitumen processing plants may be “stick-built,” or constructed from theground up at the oil sands location on which they will operate. However,disadvantages to stick-built construction may include exposure toextreme adverse weather conditions, no local labor force, poor qualitycontrol, poor productivity, lack of existing transportationinfrastructure, lack of existing utilities infrastructure, high materialtransportation costs, and inadequate raw material storage, and lack ofexisting human services and support infrastructure.

Alternatively, bitumen processing plants may be partially constructedfrom sub-assemblies or modules, e.g., pipe rack, process and/orequipment modules, that are fabricated, assembled and/or testedoff-site, and transported to the heavy industrial plant site. A singlelarge-scale bitumen processing plant may require the fabrication ofseveral hundred to more than 1,000 modules. The modules may then beindividually transported to the processing plant site for assembly.Because of the inland location of the Alberta oil sands, modules may bemoved by land or marine transportation. Marine transportation, however,is extremely limited in that only certain processing plants have riveraccess, and river access is blocked for much of the year by ice. Thus,modules are manufactured in significant population centers nearest theprocessing plants sites, namely, Fort McMurray and Edmonton. Althoughsuch towns provide some needed infrastructure, many of the disadvantagesof stick-built construction nevertheless remain with module constructionin such nearby industrial centers. Furthermore, by concentrating modulefabrication and assembly in nearby population centers, additionaldisadvantages arise, such as exacerbated labor shortages, inflated laborcosts due to scarce resources, outdoor module assembly in severe adverseweather, and exposure of town economics to single-industry jobvolatility.

Thus, there is a need for more efficient method and system of providingmodules for assembly at a heavy industrial hydrocarbon processing plantsite.

SUMMARY

A method of supplying modules to a hydrocarbon processing plant site,the method comprising establishing a large-sized module assembly site onone side of an international border; receiving raw constructionmaterials at the assembly site; receiving a standard truck module at theassembly site; assembling a large-sized module using the rawconstruction materials and the standard truck module; and sending theassembled large-sized module by land across the international border tothe hydrocarbon processing plant site for assembly.

A method of assembling a hydrocarbon processing plant, the methodcomprising rigging a large-sized module for transportation by land onone side of an international border; and sending said large sized moduleby land across the international border for assembly into a hydrocarbonprocessing plant.

A transportation logistics system comprising a server connected to anetwork; a database accessible by the server, the database containingheavy-haul transportation logistics information; and a mobile firstclient computer connected to the server via the network, the mobilefirst client computer being adapted to provide a graphical userinterface configured to allow substantially real-time updating of thedatabase with information pertaining to land routes suitable forheavy-haul transportation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates one embodiment of part of a hydrocarbon processingplant assembled from standard truck modules and large-sized modules.

FIG. 2 illustrates various module sizes.

FIG. 3 illustrates a large-sized module assembled from smaller modules.

FIG. 4 illustrates one embodiment of a module fabrication and assemblyyard.

FIG. 5 illustrates one embodiment of a module assembly line.

FIG. 6 illustrates one embodiment of a module supply chain.

FIG. 7 illustrates an exemplary method of assembling and supplyingmodules.

FIG. 8 illustrates one embodiment of a large-module transportationroute.

FIG. 9 illustrates Alberta high-load roads.

FIG. 10 illustrates seasonal pavement loading limits.

FIG. 11 illustrates one embodiment of a tractor-trailer loaded with alarge-sized module and annotated with seasonal axle loading limits.

FIGS. 12A-12E illustrates exemplary trailer payload capacities byseason.

FIG. 13 illustrates bridge loads on a heavy-haul route.

FIG. 14 illustrates allowable bridge loads on a heavy-haul route.

FIG. 15 illustrates allowable bridge loads on a heavy-haul route byseason.

FIG. 16 illustrates exemplary acceleration and deceleration limits of atractor-trailer loaded with a large-sized module.

FIG. 17 illustrates an exemplary heavy-haul transportation logisticssystem.

FIG. 18 illustrates an exemplary transportation logistics database tablecontaining bridge information.

FIG. 19 illustrates an exemplary method for updating a transportationlogistics database.

FIGS. 20A-E illustrates an exemplary user interface screens for aheavy-haul transportation logistics system.

FIG. 21 illustrates an exemplary method for determining suitablelarge-module shipping routes.

FIG. 22 illustrates an exemplary algorithm for determining suitablelarge-module shipping routes.

DETAILED DESCRIPTION

Modular Heavy Industrial Hydrocarbon Processing Plant

FIG. 1 illustrates a partial plan view of an exemplary embodiment of aheavy industrial hydrocarbon processing plant 1. As may be seen in theembodiment of FIG. 1, the processing plant 1 may be comprised of anatmospheric distillation unit 2, a light naphtha hydrotreater 3,isomerization unit 4, diesel oil hydrotreater 5, vacuum distillationunit 6, other process units that are not shown, and a system ofpiperacks 7 to transfer fluids throughout the processing plant 1.Bitumen feedstock 8 may be fed to the atmospheric distillation unit 2. Aplurality of pipe racks 7 may be used to transfer various distillatesfrom the atmospheric distillation unit 2 to other process units. Forexample, light naphtha distillate 9 may be transferred to a lightnaphtha unit hydrotreater 3, and from there to an isomerization unit 4.Diesel oil 10 may be transferred to a diesel oil hydrotreater 5. Heavyoils 11 may be transferred to a vacuum distillation unit 6. In someembodiments, isomerates 12 and heavy oil distillates 13 may be combinedto form an upgraded synthetic crude oil that may be transported toanother hydrocarbon processing plant for further processing.

In the embodiment of FIG. 1, the processing plant 1 may be assembledfrom various modules. The atmospheric distillation unit 2, light naphthahydrotreater unit 3, and diesel oil hydrotreater 5 may each be comprisedof two standard truck modules. Other units, such as the isomerizationplant 4 and vacuum distillation unit 6, may be comprised of large-sizedmodules. The pipe racks 7 may be comprised of one or more standard truckmodules and large-sized modules.

In other embodiments, a processing plant may comprise a hydrocarbonupstream extraction unit, SAGD process units, boiler/power/steam/utilityunits, gas recovery and processing units, crude oil refineries, watertreatment plant, pipeline booster station, central processing plant,compressor stations, and the like. As used herein, a “hydrocarbonprocessing plant” is an exemplary processing plant, and should not beconstrued as limiting the other types of heavy industrial plant to whichthe disclosed system and method may apply.

Module Configuration

A module may be a major section of a heavy industrial hydrocarbonprocessing plant. Modules may be provided in a variety of suitablestructural forms, such as a cube, rectangular hexahedron, or some otherpolyhedral form. A structural form may provide a framework or supportframe that allows an entire module to be lifted for placement onto atruck, railcar, ship, into shipping containers, and/or onto supportfoundations. The support frame may also support various equipment,piping and electrical conduit. The support frame may further providemodule assembly points, such as bolt plates or weldable edges, thatpermit modules to be robustly assembled into a heavy industrialhydrocarbon processing plant.

Modules may be provided in a variety of sizes. As may be seen in theembodiment of FIG. 2, a standard truck module may include those modulesof a size and weight generally suitable for commercial carriers with nospecial arrangements, such as oversize permitting, required. Forexample, a standard truck module may in one embodiment be configuredsuch that when loaded onto a standard commercial carrier, the grossweight per axle may be up to approximately 15,400 lbs, the overalllength of the truck plus load may be up to approximately 75 ft, and theheight of the load sized such that it may be up to approximately 13½ ftfrom the road surface, and the width may be up to approximately 8½ ft.Such a module may, in one embodiment, weigh up to approximately 60,000lbs (30 tons).

A standard railcar module may include those modules of a size and weightgenerally suitable for transportation on a commercial railcar. Forexample, a standard railcar module may in one embodiment may be up toapproximately 12½ ft wide, be up to approximately 12½ ft high, and be upto approximately 66 ft long. Such a module may, in one embodiment, weighup to approximately 180,000 lbs (90 tons). In other embodiments, astandard railcar module may be up to approximately 14½ ft high, be up toapproximately 13½ ft wide, be up to approximately 89 ft long, and weighup to approximately 200,000 lbs (100 tons).

An intermediate-sized module may be somewhat larger than standard truckmodules, and may require a special permit to transport over publicroads. For example, an intermediate-sized module may in one embodimentbe configured such that when loaded onto a tractor-trailer, the overalllength of the truck plus load may be up to approximately 60 ft, and theheight of the load sized such that it may be up to approximately 29½ ftfrom the road surface, and the width may be up to approximately 12½ ft,and the height may be up to approximately 9½ ft. In other embodiments,the height of the load sized such that it may be up to approximately 13½ft from the road surface, and the width may be up to approximately 23ft. Intermediate modules may include, for example, structural steelframes, empty modules with no piping or equipment installed, andsingle-level piping “sleeper” modules.

A large-sized module may be substantially larger than standard andintermediate-sized modules. In other embodiments, large-sized modulesmay be comprised of truck modules, railcar modules and/orintermediate-sized modules, as may be seen in FIG. 3. Large-sized modulemay in one embodiment be configured such that when loaded onto atractor-trailer, the overall length of the truck plus load may belimited only by the trailer configuration and road conditions, such asturning radius and gradient. The height of the load may be sized so asto be up to approximately 29½ ft from the road surface, and the widthmay be up to approximately 24 ft. In one embodiment, a large-sizedmodule may weigh up to approximately 156 tons and measures approximately24 ft wide, 25½ ft high, and 100 ft long. In another embodiment, alarge-sized module may weigh 70 tons and measure approximately 22 ftwide, approximately 22 ft high, and approximately 85 ft long. In anotherembodiment, a large-sized module may be up to approximately 120 ft long.Various large-sized modules may have different tonnages. For example, alarge-sized pipe rack module may weigh approximately 85 tons, and alarge-sized equipment module may weigh 156 tons due to differences inmodule density.

In some embodiments, large-sized modules may be larger than would fitwithin the foregoing shipping envelope. For example, a large-sizedmodule comprising equipment that is not readily divisible may not fitwithin such a shipping envelope. Large-sized modules may include, forexample, multi-level pipe racks with cable tray supports and multi-levelcable trays. In some embodiments, large-sized modules may haveprojections, such as a cable trays and platforms, that extend beyond the24 ft envelope. A large-sized module with such projections may be loadedonto a trailer such that the projections extend no less thanapproximately 13½ ft above the road surface, and extend on the curb orditch side of the road rather than on the passing traffic side. If, inone embodiment, the large-sized module comprises a dressed load, e.g.,with bolted-on ladders and platforms installed at the fabrication yard,the large-sized module may not extend beyond approximately 12 ft fromthe trailer centerline on the ditch or curb side. On the traffic side,the portion of the large-sized module above a line 45 degrees up fromthe large-sized module's horizontal centerline may not extend beyond anapproximately 12 ft radius. The portion of the large-sized module belowthe 45-degree line may not extend beyond approximately the edge of thetrailer.

Modules may be provided for a variety of processing plant sections. Forexample, a pipe rack module may be comprised of structural steel withone or more tiers of piping, electrical heat tracing (EHT), insulation,instrumentation, cable tray, wiring, lighting, and fireproofing. In oneembodiment, all work on pipe rack modules, such as hydrotesting andnon-destructive testing (NDT), may be completed as much as possiblebefore transportation to the plant site.

A process module or equipment module may be comprised of structuralsteel with one or more pieces of process equipment, platforms, piping,EHT, insulation, instrumentation, cable tray, wiring, lighting andfireproofing. In one embodiment, all work on process or equipmentmodules, such as hydrotesting, draining, drying, preservation and NDT,may be completed as much as possible before transportation to the plantsite.

Modules may be designed to allow relatively simple, quick connectionsbetween multiple modules in the field using standard piping andelectrical components to provide a complete hydrocarbon processingplant. Modules may be constructed and interconnected so as to providesupport for individual equipment, piping, and electrical wiring forpower and control. Interfaces for piping, electrical wiring and otherequipment may be provided to allow such quick interconnection. Forexample, modules may comprise pipe racks to provide for fluid flowwithin the processing plant, and for fluid interconnection betweenvarious process units and other component systems of a hydrocarbonprocessing plant.

Modules may be placed adjacent to each other in horizontal combination,vertical combination, or both, and interconnected to form a hydrocarbonprocessing plant or hydrocarbon processing plant sub-assembly. Forexample, modules may be assembled in a horizontal combination on aconcrete pad set in the ground. Alternatively, modules may be assembledinto a vertical hydrocarbon processing unit, such as a verticalcrude/vacuum hydrocarbon processing plant. In one embodiment, a verticalhydrocarbon processing unit may provide a complete crude distillationprocess system combined with a complete vacuum process system fordistillation, separation, stripping, and/or removal of petroleumfractions such as liquid petroleum gas (LPG), gasoline, naphtha,kerosene, gas-oils and residue, and particulate from crude oil.Similarly, pipe rack modules may be assembled horizontally and/orvertically.

Modules may be used to change the configuration or hydrocarbonprocessing capacity, capability or product lines of an existinghydrocarbon processing plant, or may be used to construct a newhydrocarbon processing plant.

In one embodiment, modules may comprise a thermocracking unit thatprocesses long hydrocarbon chains into smaller hydrocarbons. Crackingoccurs by breaking longer hydrocarbon chains into smaller hydrocarbonchains that are more desirable. An exemplary thermocracking process,hydrocracking, uses a feedstock such as vacuum gas oils (VGO). Thefeedstock is heated, introduced into a reactor vessel, and mixed with ahydrogen stream in the presence of a catalyst. The reaction vesseloperates at extremely high temperatures and pressures. The combinationof temperature, pressure, and the presence of free hydrogen moleculestrigger simple chemical reactions.

In another embodiment, a motor control center module may houseelectrical generation motors and their controls for supplying power toother modules. A control room module may be provided to house computersystems and other system control equipment for operating the hydrocarbonprocessing plant. The control systems may also be connected to a remotelocation, for example, via a satellite link, to allow monitoring of thefacility by an offsite team of engineers. These engineers can providenotice to control operators of potential equipment failures, review foridentification of operational errors, and provide a direct resource fortroubleshooting problems.

Other modules may wholly or partially comprise, for example, a delayedcoker unit, control system, and various other hydrocarbon processing andrelated equipment, such as cat crackers, fluidized bed cat crackers,hydrocrackers, thermal crackers, atmospheric distillation columns,vacuum distillation columns, crude oil heaters, vacuum column heaters,pumps, vacuum pumps, vacuum separators, desalinization devices, watertanks, heat exchangers, pressure tanks, stripper columns, separators,flash drums, cooling towers, hydrogen plants, hydrotreating heaters,hydrotreating columns, hydrogen separators, fire suppression equipment,once-through steam generators, pipe racks, gasifier reactor, gasifierfeed pumps, water treatment vessels, hydrocrackers, heat recovery steamgenerators, hydrogen compressors, and fractioner columns.

Possible hydrocarbon processing processes for which a modularhydrocarbon processing plant constructed according to the disclosurehereof may be used include, but are not limited to, the following: SAGDand other hydrocarbon extraction process units, atmosphericdistillation, vacuum distillation, hydrotreating, catalytic reforming,isomerization, hydrocracking, catalytic cracking, delayed coking,residue reduction, asphalt, gasoline blending, sulfur recovery, ethyleneprocessing, hydrogen production, power/utility plants, and liquidpetroleum gas (LPG) production.

Module Fabrication and Assembly

Module fabrication and assembly may include assembly of fabricatedsupport steel, pipe spool installation, equipment and instrumentinstallation (such as meters and control valves), pipe spoolhydrotesting, non-destructive examination (NDE) of weld joints, EHT,insulation and cladding, painting, fireproofing and preparation forshipment. Module fabrication and assembly may also include installationof pipe valves and fittings; installation of instrument sub-headers andassociated pneumatic tubing; installation of instrument stands,transmitters and associated winterization material; installation ofconduit and cable trays; installation of on-lighting module panels;installation of lighting receptacles and fixtures (including shades),and wiring to an on-module lighting panel; installation of conveniencereceptacles; installation and termination of cables between panels andfixtures; installation of instrument junction boxes; installation andtermination of cables between instruments and on-module junction boxes;and prewiring of instrumentation and termination in a skid edge junctionbox such that signals can be wired back to a process control systemmarshalling cabinet with multi-conductor cables once the modules areplaced on-site. Also, each module's center of gravity may be ascertainedfor transportation purposes.

FIG. 4 illustrates an exemplary module fabrication and assembly yard. Inthis embodiment, a module assembly line may be provided at a modulefabrication facility alongside other assembly lines, such as pipefabrication bays and subassembly bays. The module fabrication facilitymay include an area for receiving and storing raw materials, weldingbays, sub-assembly bays, offices, pipe-cutting stations and otherfabrication and assembly process areas.

A sheltered module assembly yard may be configured as shown in FIG. 5.As may be seen in FIG. 5, a system of movable canopies 501 may beprovided to shelter a module assembly line. Modules 502 may be mountedon large movable platforms 503 for assembly. The platforms may bemounted on rollers 504 for movement along the assembly line. A gantrycrane may be provided to assist in assembly of modules and in loading ofmodules on to a trailer for transportation to the processing plant site.

Modules may be built in a series of assembly operations remote from theheavy industrial hydrocarbon processing plant site. FIG. 6 depicts, inone embodiment, a simplified representation of the fabrication,assembly, transportation, and delivery of modules across North America.As may be seen in FIG. 6, raw materials may be supplied, and modules andcomponents may be assembled at various points along the supply chain.

In the embodiment of FIG. 6, pipe spool fabrication, structural steelfabrication, and standard truck, intermediate-sized and railcar modulefabrication and assembly may be accomplished in Mexico, such as at thecoastal town of Tampico. For example, pipe rack and equipment modulesmay be wholly or partially constructed at the Tampico yard. Themanufacturing and fabrication may occur at uncovered and/or shelteredassembly yards dedicated to such purposes. Management and supervisorsmay be from the United States, from Mexico, or some combination of USand Mexican personnel. In one embodiment, the yard may be located near arailhead and seaport. Raw materials may be transported to the Mexicoyard by rail or sea. Mexico may provide advantageous labor costscompared to the United States and/or Canada. There may be little or nocompetition between Mexican labor resources and US or Canadian laborresources. In one embodiment, Mexican labor may be qualified tofabricate certain components and assemble certain modules. Furthermore,Tampico may have substantially more advantageous weather conditions thanCanada. Assembled modules, components and sub-assemblies may betransported by truck or rail to the United States or Canada, such as toCorpus Christi, Tex., Billings, Mont., or to the final plant site forfurther work or assembly into a heavy industrial hydrocarbon processingplant.

In the embodiment of FIG. 6, assembly of other standard truck,intermediate-sized and railcar modules, or further work on modules fromMexico, may occur at Corpus Christi, Tex. in the United States.Components such as pressure vessels and API 650 tanks may beadvantageously assembled. Further, pipe spool fabrication and otherstructural component fabrication may occur at a yard in Corpus Christi.As with the Tampico yard, the Corpus Christi yard may also provide asheltered location for that work, and for testing modules. Other aspectsof construction, such as painting, metallurgical stress relief,insulation and electrical work may be performed at the Corpus Christiyard, as well. The Corpus Christi yard may be used for assembly ofmodules that require a more skilled and experienced workforce than maybe available in either Mexico or Canada. The Corpus Christi yard mayemploy temporary foreign workers, such as Canadian or Asian workers withCanadian Red Seal certification. Assembled modules, components andsub-assemblies may be transported by truck or rail to Billings, Mont.,or to the final plant site in Canada for further work or assembly into aheavy industrial hydrocarbon processing plant.

Further fabrication and assembly of modules and components may beaccomplished at a yard closer to the Alberta oil sands, yet far enoughaway to be relatively unaffected by labor and other constraints in theoil sands region. In the embodiment of FIG. 6, further work on modules,components and sub-assemblies from Corpus Christi and Tampico may beaccomplished at a sheltered assembly yard in Billings, Mont. As at theTampico and Corpus Christi yards, pipe spool fabrication may beaccomplished at the Billings yard, as well as other module andstructural component fabrication modules that may be assembled, painted,insulated and wired. Significantly, unlike at the Tampico and CorpusChristi yards, large-sized modules may be fabricated and assembled inBillings, Mont., for overland transportation to a heavy industrialhydrocarbon processing plant site or site-adjacent “supermodule”assembly yard in the Alberta oil sands region. Assembled large-sizedmodules may be transported by special heavy-haul tractor-trailer, asdescribed further below.

The Billings yard may provide a place to train and certify workers (suchaccording to the Canadian interprovincial Standards Red Seal Program)for work in Canada, and may thus providing a pool of skilled labor forfurther module assembly at a heavy industrial hydrocarbon processingplant site. Such workers may include temporary foreign workers fromvarious countries in the world. In one embodiment, US workers may betrained and certified for work in Canada. This approach may provide asubstantially larger labor pool for module construction than at theplant site. Thus, assembly of large-sized modules in Montana, andoverland transportation to the plant site advantageously avoids thelabor shortages, lower labor skill levels, adverse weather conditions,material shortages, high costs, excess transportation expenses, currencyrisks, and material storage problems that have hitherto plaguedconstruction of heavy industrial hydrocarbon processing plants in theAlberta oil sands region.

FIG. 7 illustrates an exemplary process of providing modules forassembly into a hydrocarbon processing plant. At step 701, a UnitedStates-based provider, such as a heavy construction firm, may receivestandard truck and/or railcar modules, components, raw materials and/orsubassemblies from Mexico. At step 702, the provider may further work onthe received modules, and may assemble standard truck and/or railcarmodules from the received components, raw materials and/orsubassemblies. At step 703, the provider may assemble large-sizedmodules from the standard truck and/or railcar modules created at step702. The provider may also assemble large-sized modules from thecomponents, subassemblies and/or raw materials received at step 701. Theprovider may also assemble large-sized modules from a combination ofstandard truck and/or railcar modules, components, subassemblies and rawmaterials from steps 701 and 702. At step 704, the provider may sendstandard truck and/or railcar modules into Canada for assembly at aprocessing plant site. At step 705, the provider may send large-sizedmodules into Canada for assembly at a processing plant site. The modulesand large-sized modules may be assembled and interconnected to form ahydrocarbon processing plant, such as the hydrocarbon processing plantof the embodiment of FIG. 1.

In one embodiment, many of those modules may be shipped into a“supermodule” assembly yard adjacent the heavy industrial hydrocarbonprocessing plant site. A “supermodule” may comprise various combinationsof standard truck modules, railcar modules, intermediate-sized modulesand/or large-sized modules assembled together. A “supermodule” may notbe transported by public road, but may be assembled and installed at ornear the plant site using self-propelled module transporters (SPMTs),gantry cranes and other heavy erection equipment. At the plant site,local craftsmen, such as Christian Labor Association of Canada (CLAC),may assemble the site. Also, non-union Red Seal-certified temporaryforeign workers (TFWs) may be utilized, such as those trained at theBillings yard.

In one embodiment, a transportation route from Billings, Mont. to Ft.McMurray, Canada may be provided as seen in FIG. 8. In the embodiment ofFIG. 8, a large-sized module may be transported along the followingroute from Billings, Mont. to the US-Canadian border: 32^(nd) Street,Hesper Road, Shiloh Road, Grand Avenue, 88^(th) Street, Lipp Road,S-401, Buffalo Trail, S-302, Molt Road, Popelka Road, Ballard Ivie Road,MT-3, 21 Mile Road, US-87, MT-19, US-191, MT-81, MT-80, S-223, US-2,Lothair Rd, S-343, Oilmont Road, Service Road (Swayze Road, Exit-385,I-15 to Sweetgrass port. Across the border, an exemplary route maycomprise: from Coutts, Alberta, Hwy 4, Hw 36 (at Warner, Alberta), Hwy3, Hwy 36 (again just past Taber), and to the high-load corridor to Ft.McMurray.

In other embodiments, large-sized modules may be fabricated andassembled in a another location remote from the Alberta oil sands, andtransported overland to the Alberta oil sands regions through otherlocations, such as through Missoula, Mont. For example, a large-sizedmodule may be fabricated and assembled outside the United States,transported into the United States by ship or barge, and transportedfrom the United States to the Alberta oil sands by land as describedherein.

Large-sized modules may be constructed away from the plant site for avariety of technical reasons, as well. For example, a single-piecevessel may need to be post-weld heat treated in an enclosed fabricationyard rather than welded and heat-treated at the plant site because itmay be difficult to control the quality of the heat treatment in anexposed environment. For a further example, process modules with piping,vessels, exchangers, pumps and control equipment are better assembled inan enclosed fabrication rather than out in the field to ensure properquality control. For another example, process modules may be betterfabricated at a location where one company can ensure the correctfunctioning of the overall process rather than at the plant site, wherevarious trades (e.g., electricians, welders, etc.) may complete theirpart of the assembly or installation with no regard to the overallprocess module. For yet another example, process skid modules containingsophisticated equipment may be better assembled in a specialized shopoffsite by trained workers than by less skilled field workers. Inanother example, module construction may be more safely accomplished ina controlled environment, thus avoiding exposure of workers to hazardousenvironmental conditions, such as H₂S, hot coke and limited visibility.In a final example, steel pipe-rack modules may be better fabricated ina shop rather than erected at the plant site so as to ensure thatdimensional tolerances are met.

By constructing large-sized modules away from a plant site, such as inMontana, Wyoming, Idaho, North Dakota and Washington, and shipping themby heavy trailer to the plant site, substantial labor and materialsavings may be realized. By further allocating manufacturing andfabrication of various module subassemblies to different locationsacross North America, many of the labor and materials pressures sufferedby stick-building heavy construction companies located near theAthabasca oil sands may be avoided. Use of a non-Canadian labor pool toassemble modules and large-sized modules reduces competition anddiminishment of the plant-site labor pool. Also, construction in Mexicoand the United States reduces exposure to harsh Canadian weather.Various labor pools are utilized, such as those in Canada, United Statesand Mexico. Further, in other embodiments, large-sized modules may befabricated and assembled in one or more locations remote from theAlberta oil sands, and transported overland to the Alberta oil sandsregions through other locations, such as through Missoula, Mont.

Module Transportation

In one embodiment, large-sized modules may be transported by one or moreScheuerle Combi-series trailers. Other suitable trailers may be used, aswell, such as those manufactured by Goldhofer and Nicolas. Suitabletrailers may be pulled by tractors such as those manufactured byMammoet. Suitable trailers may be steerable, load-balancing,load-distributing, having high bending moments, modular hydraulic,self-propelled and/or combined into a variety of configurations andlengths. Suitable trailers may be provided with various heavy-dutyequipment, such as long-load equipment, goosenecks, saddles, pullingdevices, loading decks, crawler-decks, drop-decks, vessel decks,drawbars, hydraulic powerpacks, side-by-side devices, hydraulic boltcouplings, long-load turntables, rear lighting crossbeams, and radiocontrols.

For example, a Scheuerle inter-combi trailer may be of a box-frameconstruction, and provided with drive axles powered by hydraulic motors.A power pack may provide metered fluid to drive the wheels in thedirection that they are pointing. A central computer may allow the axlesto turn to allow the trailer to move in a variety of directions. Thetrailer decks may be leveled, raised and lowered using hydraulicsuspension to accept and release loads. Two axles on each line maysupport the trailer structure. Each axle may have four tires, thusproviding 8 tires on a line. The trailer may be provided with hydraulicbrakes and a backup mechanical spring brake if the hydraulic brakesfail.

In one embodiment, a module may be loaded onto a tractor-trailer suchthat the shipping envelope of the tractor-trailer with the loaded moduleis up to approximately 24 feet wide, up to approximately 145 feet long,and up to approximately 29½ feet high from the road surface. In such anembodiment, the weight on the road may be up to approximately 16,100 lbsat the steering axle; up to approximately 37,500 lbs at the set of driveaxles; up to approximately 79,500 lbs at a first set of trailer axles;up to approximately 79,500 lbs at a second set of trailer axles; up toapproximately 79,500 lbs at a third set of trailer axles; up toapproximately 79,500 lbs at a fourth set of trailer axles; up toapproximately 79,500 lbs at a fifth set of trailer axles; and up toapproximately 79,500 lbs at a sixth set of trailer axles.

Moving large-sized modules by Scheuerle trailer may require substantiallogistical effort. For example, only certain roads can bear heavy loads.Traffic signals and power lines may have to be moved, traffic may haveto be rerouted, and other accommodations and permissions may have tooccur to support large-sized module transport along the network of roadsfrom the United States to the hydrocarbon processing plant site. In oneembodiment, suitable routes may be determined from a database of roadconditions and transportation guidelines, as discussed further herein.Such conditions and guidelines may include the name of the road, theroad length, various gas or service stations along the road, roadwayweight limits, the historical road conditions by season, road sizelimits, grade, traffic load, holiday travel regulations, coordinationwith emergency services, daylight hours, flag car requirements, utilityline placement, speed limits, load signage, radio communicationrequirements, lighting requirements, bridge placement, under- andover-passes, traffic light placement, peak traffic times, physicalroadside obstacles, bridge weight and size limits, seasonaltransportation bans, seasonal weight limits, axle selection and spacing,acceleration and deceleration limits, power line crossings, railroadcrossings, permit details and contact information, and varioustransportation-related regulations.

Various heavy haul routes may be planned. For example, FIG. 9illustrates some of the heavy haul routes that may be available inAlberta, Canada, as designated by the Government of Alberta Ministry ofTransportation (www.transportation.alberta.ca). Some of the routesegments may include:

High Load Corridor Route Segments Highway From At Hwy 1 SH 797 Jct 36Hwy 11 SH 815 SH 601 Hwy 14 Jct 17 Jct 21 Hwy 15 SH 834 Jct 21 Hwy 16 SH753 Jct 32 Hwy 17 Jct 14 22 km. N. of Jct 14 Hwy 19 Jct 2 Jct 60 Hwy 21Jct 15 Jct 16 Hwy 21 Jct 14 SH 625 Hwy 21 SH 601 SH 625 Hwy 22 Jct 1A 12km N. of Sundre Hwy 22 Jct 13 SH 621 Hwy 28 Jct 36 Jct 63 Hwy 29 Jct 36Jct 36 (Duvernay) (west of St. Paul) Hwy 32 Jct 16 Jct 43 Hwy 36 Jct 1Jct 45 Hwy 36 Jct 45 Jct 29 (Duvernay) Hwy 36 Jct 29 Jct 28 Hwy 39 Jct22 Jct 60 Hwy 41 Jct 45 Jct 55 Hwy 45 Jct 15 SH 831 Hwy 45 Jct 36 Jct 41Hwy 55 Jct 41 SH 892 Hwy 60 Jct 19 Jct 39 Hwy 63 Jct 28 North End of Hwy63 SH 560 Calgary SH 797 SH 597 Hwy 2A SH 815 SH 601 Hwy 11 Hwy 21 SH815 SH 597 Hwy 11 SH 621 Jct 22 SH 753 SH 625 Jct 2 Jct 21 SH 753 Jct 16SH 621 SH 797 Jct 1 SH 560 SH 831 Jct 45 Jct 28 SH 834 Jct 14 Jct 15

In some embodiments, for example, highway module payload capacity for aScheuerle-type trailer may vary by season. In Alberta, for example,payloads beyond a certain weight may be banned from the heavy-haulroutes during spring thaws, and the heaviest loads may be carried onlyduring the winter when the ground freezes.

FIG. 10 illustrates, for that example, a graph showing pavement loadingon a heavy haul route according to different seasons. As may be seen inFIG. 10, the heaviest loads may be carried deep in the winter seasonwhen the ground is frozen. During the spring season, thawing conditionsmake the ground softer and more unstable. Transportation of heavy loadsmay be banned during that time to avoid road damage and trafficobstructions. Summer and fall season conditions may permit heavier loadsto be transported, at least on some heavy haul routes, as environmentalconditions stabilize somewhat.

FIG. 11 illustrates an exemplary tractor-trailer configuration annotatedwith seasonal axle loads. As may be seen in the embodiment of FIG. 11,the steer axle weight of a heavy tractor may remain relatively constant,but the drive axle load may increase as the trailer load increases. Inthe embodiment shown, the steer axle weight may be at 7,300 kg, but thedrive axle weights may vary from approximately 17,000 kg during thespring season, when hauling heavy loads is banned, to approximately25,000 kg in the winter season, when road conditions permit heavierloads to be hauled. Increased trailer loads may require that one or moreweights be placed over the drive tires to increase traction. In theembodiment of FIG. 11, a trailer carries a large-sized module with sideelevation dimensions of 100 ft long by 25½ ft high. The weight of thelarge-sized module may vary according to seasonal road weight limits.During the spring season, for example, the large-sized module weight maytranslate to axle weights of approximately 28,000 kg. During the winterseason, the large-sized module weight may translate to axle weights ofapproximately 37,000 kg. During other times of the year, otherlarge-sized module weights may be permitted. For example, as seen in theembodiment of FIG. 11, the large-sized module weight may translate toaxle weights of approximately 32,000 kg during the summer season.

In another embodiment, a highway Scheuerle trailer module payloadcapacity may vary by season, as may be seen in the chart of FIG. 12A. Inthis embodiment of a road-style Scheuerle trailer, an axle group may beconsidered to be two axles. For example, an 8-line 2-file trailer has 4axle groups and an 8-line 4-file trailer has 8 axle groups. The chartsof FIGS. 12B-12E provide further exemplary payloads for conventional,inter-combi, “European-style” and “Road Style” Scheuerle trailers thatmay be used in some embodiments.

Furthermore, certain bridges on a heavy haul route may have certaingross vehicle weight (GVW) limits, as may be seen in the Alberta routeembodiment of FIG. 13. Visual depiction of a route in a simplified chartmay assist various parties involved in heavy hauling, such as thelarge-sized module manufacturer, heavy transportation company,processing plant owner, and governmental transportation departments, inevaluating the suitability of a given route for transportation oflarge-sized modules and other loads. For example, in transporting alarge-sized module from Billings, Mont. to Edmonton, Canada or FortMcMurray, Canada, or from Edmonton, Canada to Fort McMurray, Canada, thelarge-sized module may need to be hauled across one or more bridges.Each bridge along the route should be identified, and its GVW ratingevaluated for its capability to support transportation of thelarge-sized module. For example, the bridge on Hwy 36 over the NorthSaskatchewan River may be GVW-rated at just under 300 tons. A maximumlarge-sized module weight may be calculated by subtracting from the GVWrating the tare, or unloaded weight of tractor and trailer. For thatbridge, the large-sized module load, if being transported from BillingsMont., may be just under 200 tons.

A route planner may evaluate the maximum tonnage that a given route maysustain, and identify any bridges for which information is not availableor has not yet been obtained. In some embodiments, the GVW rating of theweakest bridge may limit the maximum large-sized module weight on agiven route, even if other bridges on that route may safely allowtransportation of greater loads. In some embodiments, the loadedtractor-trailer GVW may be less than the bridge GVW rating to provide amargin of safety. Also, some bridge surfaces may be less smooth thanothers, and may result in some bouncing of the load as it crosses, thusrequiring a larger margin of safety for dynamic bridge loading. For suchbridges, it may be desirable to travel at an even more reduced rate,such as at 2-3 mph. Furthermore, the center of gravity and loadconcentration of a module may limit a trailer payload.

In some embodiments, using scale weights rather than estimated weightsmay allow for a greater payload because of increased confidence in theactual payload weight. Furthermore, in some embodiments, to spread out aload over a greater bridge area, a longer trailer having more axles andmore space between each axle group may allow a greater payload. Forshorter bridges, for example, a trailer may be sufficiently long thatonly one axle set at a time is actually on the bridge while travelingover, thus allowing a load weighing overall greater than the bridge'sGVW rating to be transported over the bridge. And, traveling down thecenter of a bridge, rather than in the normal driving lane, may allow abridge to sustain transportation of a heavier load.

Thus, a route planner may calculate the large-sized module load thateach bridge on a route may sustain, as may be seen in the exemplaryallowable bridge loading chart of FIG. 14. Such a chart may provide aready visual representation of maximum weight limits over the route.

Furthermore, exemplary allowable bridge and pavement loads by season maybe visually depicted, as may be seen in the embodiment of FIG. 15.Seasonal limits may further limit the maximum load that a given routemay sustain.

Module transportation may be subject to acceleration and decelerationlimits. As may be seen in the embodiment of FIG. 16, a tractor 1601 maypull a trailer 1602 loaded with a large-sized module 1603. Accelerationand deceleration in the direction of travel may be limited to no morethan one fourth of the gravitational constant (32.2 ft/sec²), orapproximately 8 ft/sec². In the vertical direction, acceleration anddeceleration may be limited to no more than one-half of thegravitational constant. Lateral acceleration and deceleration may belimited, as well. It may be important to ensure that the load center ofgravity 1604 coincides with the payload center of the trailers on whichit is loaded. Excessive acceleration and deceleration, ascending ordescending gradients, curves, other road tilt and wind power may causethe load center to move away from the trailer payload center, thusincreasing the risk that the trailer and load will tip over. Limitingacceleration and deceleration, including travel around curves, and upand down hills, can help prevent the centers of gravity from moving outof alignment.

Heavy-Haul Transportation Logistics System

An embodiment of a system for heavy hauling supply chain logistics 1701may be provided, as illustrated in FIG. 17. A database 1702 having routeinformation such as that noted above may communicate with a server 1703running a route engineering software application. The database 1702 maybe a part of the server 1703, and may be managed by through anadministrative client computer 1704. A route planner may drive alongvarious roads, and use a laptop computer 1705 to communicate with theserver 1703 and database 1702 via a communications network 1706 toidentify, confirm and/or update road conditions, and to store variousheavy haul routes in the database 1702. For example, a route planner mayidentify or confirm bridge attributes, and update a database table suchas illustrated in the embodiment of FIG. 18. In that embodiment,attributes such as bridge length and rail height may be considered.Other parties that may need access to route information, such as atransportation company's regulation compliance officer, may access thedatabase via client 1707 computer over the network, as well. Forexample, a route planner may note various road hazards, turn distances,traffic signals, bridge GVW limits and other items of interest. Duringtransportation of a large-sized module, alternate routes may bedetermined on the fly if the planned route proves unworkable due, forexample, to unexpected environmental conditions or traffic accidents.

In an embodiment, the route engineering software application may beprovided as a server-side application accessible via a client computer.The application may operate according to the flowchart of FIG. 19. Asmay be seen in FIG. 19, the application may allow a user to updateand/or populate a database with route information, such as roadconditions and transportation guidelines. In step 1901, the applicationreceives a user's username and password. A graphical user interface,such as the login screen 2010 illustrated in FIG. 20A that prompts auser to enter a user ID and password in fields 2011 and 2012, may beprovided for this step. In step 1902, the user's ID and password may beverified, thus providing the user with access to the database. In step1903, the applications may allow a user to interactively review andinput data. The user may be provided with a screen 2020, such as thatillustrated in FIG. 20B, with fields 2021, 2022, 2023, and 2024 forinputting bridge length, bridge rail height, bridge width and number oflanes on the bridge, and/or drop-down menus 2025 that allow the user toreview and input route information. In step 1904, the application mayupdate the database and save the changes.

In an embodiment, a user may use the route engineering softwareapplication for assistance in determining one or more optimal routes formodule transportation. An optimal route may be one that minimizes traveltime, does not have excessive gradients, minimizes traffic disruptions,requires that relatively few traffic signals be used, avoids denselypopulated areas, and/or the like, for a module. As seen in the exemplaryprocess of FIG. 21, in step 2110, a user may input module shippingenvelope information, such as the shipping envelope of a tractor-trailorloaded with a large-sized module weighing 100 tons, via a screen 2030such as that illustrated in FIG. 20C. In step 2111, the user may inputthe route start point and route end destination via a screen 2040 suchas that illustrated in FIG. 20D. For example, the route may start at afabrication yard in Billings, Mont., and end at a plant site near Ft.McMurray in Alberta, Canada. In step 2112, the user may review astep-by-step direction list and/or visual map of route options that maybe suitable for transportation of that particular module. In oneembodiment, a direction list or map may be provided via a screen 2050such as that illustrated in FIG. 20E. In one embodiment, an optimalroute may be emphasized on a map. In step 2113, the user may reviewroute-based road conditions and transportation requirements, such aswhether a permit would be required for the particular load, whether apilot car would be required, where traffic lights are, and the like.

In one embodiment, the application may use an algorithm such as thatdepicted in FIG. 22, to determine an optimal route for a module. In step2210, module shipping envelope values and route information values maybe set based on information input by the user. Such shipping envelopevalues may include a length value, a width value, a height value, anoverall_weight value, a trailer_weight value, a trailer_axle_countvalue, a trailer_axle_distance value, a route_start value, and aroute_end value, among other values. The length value may represent theoverall length of a tractor-trailer with payload. The width value mayrepresent the overall width of the tractor-trailer with payload. Theheight value may represent the overall height of the tractor-trailerwith payload. The trailer_weight value may represent the weight of thetrailer with payload. The trailer_axle_count value may represent asingle axle or a set of axles. The trailer_axle_distance value mayrepresent the horizontal distance between individual axles or betweenaxle sets. The route_start value may represent a physical startinglocation for payload transportation. The route_end value may represent aphysical ending location or payload destination.

In step 2212, an average_GVW value may be calculated by dividing thetrailer_weight value by the trailer_axle_count value. The applicationmay allow a user to set an actual GVW for a given axle or axle setinstead of allowing the algorithm to calculate an average GVW. A usermay desire to input an axle GVW value of a load has a center of gravitythat does not coincide with the load's dimensional center.

In step 2214, all possible routes may be determined between theroute_start value and the route_end value. In step 2216, all possibleroutes may be rank-ordered from shortest route to longest route. In oneembodiment, Dijkstra's algorithm or some variant thereof may be used tocalculate the shortest route, the second shortest route, the thirdshortest route, etc. In one embodiment, a route segment may be definedat each end by a route node. Each intersection in a network of roads maybe deemed a route node and given a value to allow route determination.Other route nodes may include, for example, the route_start value,route_end value, each end of a bridge. Thus, a network of roads may bemodeled as a network of route nodes. If the shortest route is desired,each road segment may be weighted according to its length, e.g., theshorter the road, the greater the segment is weighted. The shortestroute may be determined by starting with the route_start value,determining the closest node to define a first route segment,determining the next closest node to determine a second route segment.The shortest route may be determined by the series of road segmentssumming to the greatest weight. Alternatively, the shortest route maycomprise the road segments between the route_start node and theroute_end node having the shortest summed length.

In step 2218, the shortest route may be evaluated for suitability fortransportation of a given module within the specified shipping envelopeby comparing values such as the length value, width value, height value,overall_weight value, average_GVW value against the route infatuationfor the first route segment, i.e., the route segment defined at one endby the route_start node (first node) and defined at the other end by theby the next route node (second node) along the route. In step 2220, ifthe comparison returns a positive value for the first route segment,i.e., the load is compatible with the first route segment, then thesecond route segment may be similarly compared in step 2222. The secondroute segment may be defined by the second route node and the next routenode (third node) along the route. If that comparison returns a positivevalue, then the third route segment may be similarly compared, then thefourth route segment, and so forth until either all route segmentsreturn a positive value, or until a negative value is returned. Forexample, a negative value may be returned if a bridge along the route isnot rated to carry the load, i.e., the load is incompatible with theroute segment that includes the bridge.

If a comparison returns a negative value for a route segment, then thesecond shortest route is evaluated at step 2224, starting with the firstroute segment of the second shortest route, then the second routesegment, and so forth until each suitable route is determined. Aftereach suitable route is determined, at step 2226 the application mayprovide the user with a visual indication of the shortest qualifyingroute, or generate a list of directions for that route, such asaccording to the screen 2050 of FIG. 20E. Alternatively, the applicationmay first display on the user's screen the shortest route compatible theshipping envelope requirements, and make the other compatible routesavailable via drop-down menu. The route may then be printed, transmittedto a governmental permitting office via email, or otherwise shared.

The route engineering software application may rely on commerciallyavailable mapping software, such as Google Maps, or Telenav software,for basic route information, such as intersection-to-intersectionmileage, and may overlay heavy hauling route info nation from a databaseto further specify an optimal route.

Any suitable mobile computer, such as a laptop, cell phone, PDA or othersuitable device, may be used to communicate with the database andserver. Various functions and aspects of embodiments of this disclosuremay be implemented in hardware, software, or a combination of both, andmay include multiple processors. A processor is understood to be adevice and/or set of machine-readable instructions for performingvarious tasks. A processor may include various combinations of hardware,firmware, and/or software. A processor acts upon stored and/or receivedinformation by computing, manipulating, analyzing, modifying,converting, or transmitting information for use by an executableprocedure or an information device, and/or by routing the information toan output device. For example, a processor may use or include thecapabilities of a controller or a microprocessor, or it may beimplemented in a personal computer configuration, as a workstation, orin a server configuration.

Further, various conventionally known data storage and memory devices,for example, cache memory, may also be used in the computer-implementedsystem and method of this disclosure, as may conventional communicationsand network components. Network configurations may include wired localarea network (LAN), wireless network topologies (WLAN), the interne, orcellular communication networks, for example.

Implementations of the foregoing system may be implemented in digitalelectronic circuitry, or in computer software, firmware, or hardware,including the structures disclosed in this specification and theirstructural equivalents, or in combinations of one or more of them.Implementations of the foregoing system may be implemented as one ormore computer program products, i.e., one or more modules of computerprogram instructions encoded on a computer-readable medium for executionby, or to control the operation of, data processing apparatus. Thecomputer-readable medium may be a machine-readable storage device, amachine-readable storage substrate, a memory device, a composition ofmatter effecting a machine-readable propagated signal, or a combinationof one or more of them. The term “data processing apparatus” encompassesall apparatus, devices, and machines for processing data, including byway of example a programmable processor, a computer, or multipleprocessors or computers. The apparatus may include, in addition tohardware, code that creates an execution environment for the computerprogram in question, e.g., code that constitutes processor firmware, aprotocol stack, a database management system, an operating system, or acombination of one or more of them. A database may be of any suitabletype, such as a relational database.

A computer program (also known as a program, software, softwareapplication, script, or code) may be written in any form of programminglanguage, including compiled or interpreted languages, and it can bedeployed in any form, including as a stand-alone program or as a module,component, subroutine, or other unit suitable for use in a computingenvironment. A computer program does not necessarily correspond to afile in a file system. A program may be stored in a portion of a filethat holds other programs or data (e.g., one or more scripts stored in amarkup language document), in a single file dedicated to the program inquestion, or in multiple coordinated files (e.g., files that store oneor more modules, sub-programs, or portions of code). A computer programmay be deployed to be executed on one computer or on multiple computersthat are located at one site or distributed across multiple sites andinterconnected by a communication network.

The processes, algorithms and logic flows described in thisspecification may be performed by one or more programmable processorsexecuting one or more computer programs to perform functions byoperating on input data and generating output. The processes and logicflows may also be performed by, and apparatus can also be implementedas, special purpose logic circuitry, e.g., an FPGA (field programmablegate array) or an ASIC (application-specific integrated circuit).

Processors suitable for the execution of a computer program include, byway of example, both general and special purpose microprocessors, andany one or more processors of any kind of digital computer. Generally, aprocessor will receive instructions and data from a read-only memory ora random access memory or both. The essential elements of a computer mayinclude a processor for performing instructions and one or more memorydevices for storing instructions and data. Generally, a computer mayalso include, or be operatively coupled to receive data from or transferdata to, or both, one or more mass storage devices for storing data,e.g., magnetic, magneto-optical disks, or optical disks. However, acomputer need not have such devices. Moreover, a computer can beembedded in another device, e.g., a mobile telephone, a personal digitalassistant (PDA), a mobile audio player, a Global Positioning System(GPS) receiver, to name just a few. Computer-readable media suitable forstoring computer program instructions and data may include all forms ofnon-volatile memory, media and memory devices, including by way ofexample semiconductor memory devices, e.g., EPROM, EEPROM, and flashmemory devices; magnetic disks, e.g., internal hard disks or removabledisks; magneto-optical disks; and CD-ROM and DVD-ROM disks. Theprocessor and the memory can be supplemented by, or incorporated in,special purpose logic circuitry.

To provide for interaction with a user, implementations of the foregoingsystem may be implemented on a computer having a display device, e.g., aCRT (cathode ray tube) or LCD (liquid crystal display) monitor, fordisplaying information to the user and a keyboard and a pointing device,e.g., a mouse or a trackball, by which the user can provide input to thecomputer. Other kinds of devices may be used to provide for interactionwith a user as well; for example, feedback provided to the user can beany form of sensory feedback, e.g., visual feedback, auditory feedback,or tactile feedback; and input from the user can be received in anyform, including acoustic, speech, tactile or near-tactile input.

Implementations of the foregoing system may be implemented in acomputing system that includes a back-end component, e.g., as a dataserver, or that includes a middleware component, e.g., an applicationserver, or that includes a front-end component, e.g., a client computerhaving a graphical user interface or a Web browser through which a usermay interact with an implementation of the subject matter described inthis specification, or any combination of one or more such back-end,middleware, or front-end components. The components of the system may beinterconnected by any form or medium of digital data communication,e.g., a communication network. As noted above, examples of communicationnetworks include a local area network (“LAN”) and a wide area network(“WAN”), e.g., the Internet.

The computing system may include clients and servers. A client andserver may generally be remote from each other and may typicallyinteract through a communication network. The relationship of client andserver may arise by virtue of computer programs running on therespective computers and having a client-server relationship to eachother.

While this specification contains many specifics, these should not beconstrued as limitations on the scope of the disclosure or of what maybe claimed, but rather as descriptions of features specific toparticular implementations of the disclosure. Certain features that aredescribed in this specification in the context of separateimplementations can also be implemented in combination in a singleimplementation. Conversely, various features that are described in thecontext of a single implementation can also be implemented in multipleimplementations separately or in any suitable subcombination. Moreover,although features may be described above as acting in certaincombinations and even initially claimed as such, one or more featuresfrom a claimed combination can in some cases be excised from thecombination, and the claimed combination may be directed to asubcombination or variation of a subcombination.

Similarly, while operations may be depicted in the drawings in aparticular order, this should not be understood as requiring that suchoperations be performed in the particular order shown or in sequentialorder, or that all illustrated operations be performed, to achievedesirable results. In certain circumstances, multitasking and parallelprocessing may be advantageous. Moreover, the separation of varioussystem components in the implementations described above should not beunderstood as requiring such separation in all implementations.

Thus, particular implementations have been described. Otherimplementations are within the scope of the following claims.

1-20. (canceled)
 21. A method of assembling a hydrocarbon processingplant, the method comprising: rigging a large-sized module fortransportation by land on one side of the US-Canadian border; andsending said large sized module by land across the US-Canadian borderfor assembly into a hydrocarbon processing plant.
 22. The method ofclaim 21, wherein the large-sized module comprises at least one of astandard truck module, a railcar module and an intermediate-sizedmodule.
 23. The method of claim 22, wherein the large-sized modulefurther comprises raw construction materials.
 24. The method of claim21, wherein the large-sized module weighs in the range of about 75 toabout 156 tons.
 25. The method of claim 21, wherein the large-sizedmodule has a width between about 22 ft and about 24 ft; a height betweenabout 22 ft and about 25½ ft; and a length between about 85 ft and about120 ft.
 26. The method of claim 21, wherein the large-sized modulecomprises at least part of a isomerization plant or a vacuumdistillation unit.
 27. The method of claim 21, wherein the large-sizedmodule is in the structural form of one of a cube and a rectangularhexahedron.
 28. The method of claim 21, wherein rigging a large-sizedmodule comprises lifting the large-sized module for placement on to atruck or railcar, into a shipping container, or onto a movable supportfoundation.
 29. The method of claim 21, wherein the large-sized modulecomprises a support frame which comprises assembly points that permitthe large-sized module to be assembled with at least one other module aspart of a hydrocarbon processing plant.
 30. The method of claim 21,wherein the large-sized module comprises multi-level pipe racks withcable tray supports and multi-level cable trays.
 31. The method of claim21, wherein the large-sized module comprises at least one projection,wherein rigging the large-sized module for transportation by land on oneside of the US-Canadian border comprises loading the large-sized moduleonto a trailer such that the at least one projection extends no lessthan approximately 13.5 ft above the road surface and extends on a curbor ditch side of a road.
 32. The method of claim 21, wherein thelarge-sized module comprises a dressed load and extends up toapproximately 12 feet beyond the trailer centerline on a ditch or curbside.
 33. A method of assembling a hydrocarbon processing plant, themethod comprising: performing hydrotesting and non-destructive testingon a module; rigging the module for transportation by land on one sideof the US-Canadian border; sending said module by land across theUS-Canadian border for assembly into a hydrocarbon processing plant; andassembling the module with at least one other module to form thehydrocarbon processing plant.
 34. The method of claim 33, wherein themodule comprises one of a standard truck module, a standard railcarmodule, an intermediate-sized module, a large-sized module, and asupermodule.
 35. The method of claim 33, wherein the module comprisesstandard piping and electrical components to allow relatively simple,quick connections between the module and the at least one other module.36. The method of claim 33, wherein assembling the module with the atleast one other module to form the hydrocarbon processing plantcomprises placing the module adjacent to the at least one other modulein one of a horizontal combination and a vertical combination.
 37. Themethod of claim 33, wherein the hydrocarbon processing plant isconnected with an existing hydrocarbon processing plant.
 38. The methodof claim 33, further comprising fabricating and assembling the module,wherein fabricating and assembling the module includes at least one offabricating support steel, installing pipe spool, installing otherequipment and instruments, installing insulation and cladding, painting,fireproofing and preparing for shipment.
 39. A method of assembling ahydrocarbon processing plant, the method comprising: receivingcomponents and subassemblies from Mexico, assembling standard truck andrailcar modules from said components and subassemblies; assembling alarge-sized module from a combination of one or more of the standardtruck and railcar modules; rigging the large-sized module fortransportation on one side of the US-Canadian border; sending saidlarge-sized module across the US-Canadian border; and assembling thelarge-sized module with at least one other module to form thehydrocarbon processing plant.
 40. The method of claim 39 wherein sendingsaid large-sized module across the US-Canadian border comprisestransporting the large-sized module on a trailer pulled by a tractor,wherein the trailer is at least one of steerable, load-balancing, andload-distributing.